Unraveling the potential of Fe-6.5Si Cold Spray laminates

This study explores the development of cold-spray-deposited Fe-6.5 wt.%Si for soft magnetic material applications. We present experimental evidence for the successful deposition of Fe-6.5 wt.%Si powder via cold spray, emphasizing the role of carrier gas in optimizing deposition performance for high-temperature materials. Detailed scanning electron microscopy, energy dispersive spectroscopy, and electron back-scattered diffraction analysis reveal the impact of annealing on enhancing magnetic performance through grain growth and stored-strain relaxation. Additionally, the fabrication and analysis of a dual-layer gradient composition, consisting of Fe-3.5 wt.%Si and Fe-6.5 wt.%Si, is successfully demonstrated and characterized using scanning electron-based microscopy. These findings provide insights into leveraging cold spray technology as an additive manufacturing approach for developing magnetic laminates.